Protective Foam Packaging Suppliers & Manufacturers

Protective foam types and cushioning performance

Protective foam packaging is used inside corrugated shipping boxes to absorb shock and vibration during transit — protecting fragile or high-value products from damage. The main foam materials used in protective packaging are: EPS (expanded polystyrene) — the most widely used foam packaging material globally — moulded into custom shapes to fit the product exactly, providing excellent cushioning at very low weight and cost. EPS is used for consumer electronics, household appliances, industrial equipment, and fragile consumer goods. The primary drawback is end-of-life — EPS is difficult to recycle in standard streams and is banned from certain applications in some jurisdictions. EPE (expanded polyethylene) — a closed-cell polyethylene foam produced in sheets, rolls, planks, and custom-cut shapes — provides excellent cushioning, moisture resistance, and chemical resistance. EPE foam is softer and more flexible than EPS — used for wrapping delicate items (glassware, ceramics, electronics), as corner and edge protectors, and as inter-layer padding. EPE is recyclable in PE foam recycling streams. EVA (ethylene-vinyl acetate) foam — a closed-cell foam with excellent cushioning, flexibility, and durability — used for premium consumer electronics inserts, sports protective pads, medical device packaging, and carrying case inserts where a soft, durable feel is required. Polyurethane (PU) foam — either rigid or flexible grades — used for custom-moulded inserts for high-value equipment, scientific instruments, and medical devices where close-fit cushioning and chemical resistance are required. PU foam-in-place systems (two-component systems that foam around the product inside the box) are used for very irregular-shaped high-value products.